SafeStackingandStorage

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Published by the Occupational Safety and Health ServiceDepartment of LabourWellingtonNew Zealand

ISBN 0-477-03449-7

First published: 1985Reprinted: 1988

Revised for OSH web site: 1999

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Contents

Introduction and Scope ................................................................. 5

A Safe Work System ...................................................................... 6

Floors and Supporting Surfaces ................................................... 7

Stock Holding Structures .............................................................. 8

Pallet Construction and Loading ................................................. 8

Positioning of Stacks ...................................................................... 9

Size and Shape of Stacks ............................................................. 11

Stability and Bonding of Stacks ................................................. 12

Stacking Different Types of Goods ............................................. 13

Rules for Destacking .................................................................... 16

Segregation of Stock .................................................................... 17

Fire Safety .................................................................................... 19

Materials Handling Equipment .................................................. 21

Safe Stock Movement .................................................................. 22

Automated Storage ...................................................................... 23

Housekeeping ............................................................................... 23

Lighting ........................................................................................ 24

Noise .............................................................................................. 24

Protective Clothing and Equipment .......................................... 24

Training of Employees ................................................................. 24

Appendix: Incompatible Chemicals ........................................... 25

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W hatever the nature of yourbusiness, it is likely to

involve the stacking and storage ofgoods and materials. Every yearaccidents occur while goods arebeing stacked or destacked and putinto or taken out of storage. Manyof these accidents are serious—someare fatal.

This booklet is designed tohelp employers and employees todevelop safe and effective methodsfor stacking and storage and so meettheir obligations under health andsafety legislation.

There is an enormous varietyof storage systems and stackingmethods in use today. Materialshandling equipment, too, isextremely diverse, ranging fromhand trolleys through various typesof forklift truck to sophisticatedwarehouse robots.

Obviously, this booklet cannotdeal with all these in detail.However, it does set out the generalrequirements and principles for safestacking and storage which apply

irrespective of the particular systemsused.

The advice in this booklet isintended to cover all types of goodsand materials, with the exception oftimber and loose bulk materials suchas sand or grain, which are thesubject of separate publicationsissued by the Department of Labour.Also, it does not cover the storageof dangerous goods and explosiveswhich are subject to:— The Dangerous Goods Act 1974— The Dangerous Goods Regula-

tions 1958— The Dangerous Goods Class 2

Gases Regulations 1980— The Explosives Act 1957— The Explosives Regulations

1959.Advice on the legislative

provisions covering these goods canbe obtained from the OccupationalSafety and Health Service.

Dangerous substances notfalling within the above legislation,should be stored in accordance withthese guidelines.

Introduction and Scope

Platform truck

Hand truck

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A Safe Work System

E mployers must take allreasonable steps to ensure that

all goods, materials, substances andequipment in workplaces are sostacked, stored, secured, and keptthat they do not constitute a dangerto persons in their vicinity during thecourse of daily operations and in anearthquake.

Such steps should ensure theseitems cannot, whether of their ownaccord, or by virtue of any externalforce (intentionally applied orotherwise), so flow, move, roll, orcollapse, as to constitute a danger topersons in their vicinity.

All workers who are or may beresponsible for stacking, storing,securing, or keeping any goods,materials, substances, or equipmentrequire full training in safe methodsof doing so.

Given the great diversity ofgoods and materials to be stored, andthe wide range of storage methodsand handling equipment in use, howcan these obligations best be met?

The answer lies in developinga safe system of work that willintegrate the three main componentsof people, materials and machinerywithin a safe and healthy workingenvironment. We shall look at eachof these in turn.

PEOPLE

People, of course, are thecritical factor. In safety and healthwe are looking mainly at injury anddamage to people (concepts of losscontrol and risk management are notforgotten). Also, it is largely peoplewho perpetrate such injury anddamage.

A safe work system relies on:(a) Adequate training and instruc-

tion for all the workforce;(b) Comprehensive planning, incor-

porating the views and opinionsof those who will operate thesystems whenever possible;

(c) Adequate supervision and con-trol; and

(d) Adequate information to enablethe workforce to carry out theirtasks in a safe and healthy man-ner.

One way of covering the aboveis to determine the important criteriafor safety and to set specificparameters which may be used, suchas planning, the provision ofinformation, training and instruction,and to set the framework forsupervision and control.

MATERIALS

The basic materials handlingand storage systems common to awide range of stores and warehousesare pallets and racking systems.

Accidents associated directlywith pallets occur for five mainreasons:(a) Poor pallet design;(b) Poor pallet construction;(c) Use of an unsuitable pallet for

the load or storage method;(d) Continued use of damaged pal-

let; and(e) Bad handling.

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Floors and Supporting Surfaces

There are basically six reasonsfor a racking system failure, eitheracting singly or in combination:

(a) Design fault i.e. rack is inher-ently unsafe;

(b) Installation fault;

(c) Materials handling equipmentfault;

(d) Materials handling equipmentoperator fault;

(e) Supervision and control fault;and

(f) Store or warehouse structuralfault.

being used in the wrong place by thewrong people.

ENVIRONMENT

The essential need is toincorporate environmentalconsiderations such as heating,lighting and ventilation into theoverall work system.

CODE OF PRACTICE

Not all recommendations forsafe stacking and storage in thisbooklet may be relevant to yourworkplace. And, there may bespecial conditions or requirementsin your workplace that this bookletdoes not cover in detail. It isrecommended that companiesprepare their own in-house code ofpractice for stacking and storage,taking into account the particularmaterials handling and storagesystems in use.

T he safe load for every floorshould be known and strict

supervision should be exercised toprevent this limit being exceeded.

As a general rule, a level flooris essential. However, where largestacks are regularly built, it is anadvantage if the floor on the site foreach stack is given a fall to the centrefrom all sides.

Timber, concrete or othersurfacing may be required to supportstored materials off the ground.

Floors or surfaces required to

EQUIPMENT

Because of the bewilderingrange of equipment available in anincreasingly competitive market, itis better to simplify the reasons forfailure. Basically, accidents occurbecause of the wrong equipment

support stacks, shelving, racks orother means of storage should becapable of sustaining the intendedload together with shock loads.

If there is a possibility of thestored material becomingwaterlogged through rain or afterextinguishing a fire, due allowanceshould be made for this extra weight.The supporting surface should alsobe sufficiently strong to withstandthe effects of any damage to ordeterioration of stored materials.

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P allets should be of soundconstruction, and be of

adequate strength for the loads andconditions under which they areused. Where pallet loads are stackedtier on tier, the lower pallets shouldbe of suitable strength and in goodcondition and the unit loads mustbe able to support the weight above.

Stock Holding Structures

R acks, shelving, bins, hoppersand other structures for the

storage of materials should beadequately designed to support andcontain the materials for which theyare used. Allowance should be madefor the possibility of stored materialsbecoming waterlogged, and forshock loads from placing materialsor from accidental contact byhandling equipment.

When partitions are used toincrease storage capacity, or to

separate stored materials, theyshould be adequately designed andbe of sufficient strength to containthe stored material safely.

Fire-protective partitionsshould be used between stored itemsof differing vulnerability to fire.

The corners or ends of shelvingand racks should be protected fromdamage by forklift trucks ormechanised equipment by steelposts, angle irons or other means.

Pallet Construction and Loading

Storage bin Fire-protective partitions

Pallet

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S tacks should not be built within450 mm of a wall. Most building

and party walls are not retainingwalls and may not withstand thepressure set up by stacks laid againstthem. A 450 mm gap between thestack and the wall also enables theconstruction and the condition ofstacks to be checked.

The stability of stackedpallets or unit loads should bemaintained by suitable bonding,avoiding excessive stack heights,to ensure that the contents of anypallet or unit load cannot collapse.The stability and structural strengthof each pallet or unit load shouldbe assured by bonding, taping,shrink wrapping or other means.

When pallet or unit loads ofcartons or sacks are stacked, care

should be taken that they are notdamaged by equipment.

Pallets or other supports usedfor forming unit loads should beregularly inspected for damage andwear. Items which could causedamage to materials should be takenout of use until repaired, or bedestroyed.

Reference should be made toNZS 2010: 1970 Specification forflat pallets for materials handling.

Positioning of StacksStacks should not be created

where any part will be within 1.5 mof a rail track. This clearance shouldbe continued all the way along thestack.

Extra care should be taken ifthe storage area is subject tovibration from rail or road traffic,outside or inside the premises.

Access for loading

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Care should also be taken instacking material in the vicinity ofmachinery or operations whichcause vibrations. Some objects areliable to creep and lose stabilityunder the influence of vibration.Sacks or bales made of syntheticmaterials are particularlysusceptible, especially when firstused. (Impregnation with wax canhelp to overcome this problem.)

Stacks, shelving and otherfixtures for holding or storingmaterials should be so laid out anddesigned that there is sufficientaccess for safe loading andunloading by either manual ormechanical means.

Storage areas should bespecifically designated, be clearlymarked, and be in the charge of aresponsible employee. Aisles shouldbe clearly marked, be of ample widthfor the type of storage, and be keptfree from obstacles and wastematerials. Stacks should not becreated which will block gangways,aisles, walkways, thoroughfares, and

particularly doors and exits.Stacks should have clear

spaces of at least 1 m on all sides,apart from walls, where a 450 mmspace should be allowed. Goodsmust not be stacked within 1 m ofthe ceiling, roof or sprinkler heads.

Base areas and heights ofstacks should be kept as small ascircumstances permit. Goods shouldbe kept well clear of light fittings,heating pipes and appliances,firefighting and alarm equipment,and doors.

No stack, shelving, fixture orother means of storage should beplaced in a position, or extended inheight, so that a person climbing onto it or removing stored goods, eithermanually or mechanically, can comeinto contact with live electricalwiring or unfenced machinery.

No material should be loadedor unloaded from stacks, shelving orfixtures if there is a risk of workersdirectly or indirectly contactingunfenced machinery, or touchinglive electrical wiring, until that

Clearways in a store: exits are sitedat each end

Lane and aisle markings

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machinery or wiring is isolated ormade safe.

Storage racks and shelvesshould preferably be non-combustible and not prone to retainwater.

Where unpalletised material,which is otherwise secure, is handledby a crane or forklift truck, it shouldbe placed on battens or other devicesto aid the use of slings or forks.

Suitable means should be usedto protect workers from injury dueto sharp corners, projections or edgeson structures and/or stored material.Corners of stored material should beclearly marked.

Safe access, by means ofladders, platforms or walkways,

must be provided for workersrequired to climb or remove goodsfrom stacks, shelves and fixtures. Onoccasions, it may be necessary toerect scaffolding.

Safety belts are useful aidswhen dealing with high stacks andawkward shapes.

Work platforms used inconjunction with forklift trucks toelevate workers should be designedand constructed in accordance withNZS 5426: 1980 Part 1 Workplatforms—low-lift and high-lifttrucks.

Markings on labels and signsfor the identification and selectionof materials and goods should beclear and easy to read.

Size and Shape of Stacks

T he size and shape of a stackdepends on the storage space

available and on the size, shape,bulk, weight, rigidity or fragility ofthe articles to be stored.

The following are thecommonest forms of stack:

Column—Single articlesplaced one above the other.

Square—Any stack, otherthan a column, with all sides vertical.(Note the stack does not have to be‘square’ in the ordinary sense of theword.)

Pyramid—A stack in whichthe plan area is reduced in everysucceeding tier.

Stepped—Stacks with two ormore adjacent tiers of the same areaand each succeeding group of tiersof a smaller area than the group onwhich it is set.

Triangular—Stacks inpyramid or stepped form on two

Column stack

Square stack

Pyramid stack

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opposite sides, the other two sidesbeing vertical.

Lean-to—Pyramid orstepped on one side and vertical onthe other three sides. (Note the termdoes not mean that the stack actuallyleans against a support.)

It is important to rememberthat the aggregate weight of the stackis borne by the lowest tier, which, of

course should be strong enough tobear the superimposed load.

Untidy stacks offend the eyeand are rarely safe by construction,since it is usually bad methods ofconstruction that cause theuntidiness.

If a stack appears to beunstable, it should be immediatelybroken down and rebuilt properly.

Stable construction of the stack isentirely dependent upon thefollowing factors:— Safe relation of height to dimen-

sion of base;— Sound interlocking of the goods;— Contents of the sacks or cartons;— Compact construction and

avoidance of transfer stress inany dunnage used for artificialbonding;

— Shape of articles e.g. meat car-casses;

— Determination of the aggregateweight to be borne by the com-ponents in the lowest tier of thestack;

— Good placing of every compo-nent forming part of the stack,with special care taken to avoidoverhang on any side or end ofa stack intended to be vertical.

Stability and Bonding of StacksResistance to collapse, strength

and the stability of stacks should bemaintained by bonding, stepping,tying or other means. The ratio ofheight to base dimensions of largestacks should be correctlyproportioned so that failure of partor whole of the stack does not occur.

Experience has shown that theheight to base ratio of anunsupported stack should not exceed3:1. As most stacks are erected byvisual alignment, a slight error incalculation near the base can easilyresult in a barely noticeableoverhang, with a resultant loss ofstability. However, where effectivebonding can be achieved, and wherethere is a good frictional gripbetween the contacting surfaces, theratio of height to base can be safelyincreased to 4:1.

Stepped stack Triangular stack Lean-to stack

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The shape of goods orpackages to be stacked will have agreat bearing on the type of bondingused. When one dimension isappreciably greater than the othertwo, it will be possible to use naturalbonding, i.e. to secure stability byinterlocking the articles themselves.In other circumstances it will benecessary to introduce othermaterials (e.g. canvas sheets,battens, piling sticks, etc.) to preventmovement of the articles stacked:this is known as artificial bonding.

Stacking Different Types of Goods

Outdoor stacks are affected byweather conditions such as rain,wind, frost and sun. Theseconditions can greatly influence thestability of stacks over time andshould be taken into consideration.

Materials which could bedislodged or blown off the top of astack under windy conditions shouldbe tied down or otherwise restrained.If tarpaulins are used to secure orprotect the stacks, they should befastened to independent anchorage,not to the stack itself.

BAGGED GOODS

The first tier should be soarranged that the bags can be spreadflat, and the same should be done insucceeding tiers. Interlocking shouldbe used if possible. Where possible,the mouths of the bags should be onthe inside of the stack.

Bagged material of differingsizes and shapes (e.g. seeds,granules, pellets etc.) should not bestacked on top of each other unless

proper precautions are taken toprevent movement by settling orvibration.

Pallets with spacers or someform of horizontal bonding should beused if there is a risk of suchmovement or if it is intended ornecessary to stack high.

Special precautions should betaken with synthetic bags or sacks,which have a tendency to slip whennew.

An outdoor stack secured by tarpaulins

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CARTONS

Careful consideration shouldbe given to the weight of stacks ofcartons. Dampness will reduce thestrength of cartons, and a damp flowmay well lead to damage of thelowest tier and ultimate collapse ofthe stack. Interlocking (e.g. thebricklaying method) can be used instacking cartons.

CASES (BOXES)

As most boxes are reinforcedwith external battens, care should betaken to see that the battens bear theweight, not the box.

BALES

Bales should be stacked withcare to ensure their stability.Attention should be paid to possiblevibration, and if possible stacksshould lean into their centre. Extracare should be taken with syntheticbales, which have a tendency to slipwhen new.

FROZEN CARCASSES

Because of their shape,carcasses lend themselves to a formof interlocking and this methodshould be used if possible, togetherwith pallets with spacers or some

Stacking baggedgoods

Frozen meat store

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form of horizontal bonding. Asuitable type of mesh netting can beused to retain carcasses on pallets ifnecessary, provided it meets hygienerequirements.

COILED WIRE

Coiled wire may be stackedhorizontally or vertically. Wedges orother supports must be used toprevent the stack from spreading.

GLASS BOTTLES ANDJARS

Care should be taken stackingbottles and jars, whether full orempty. Small quantities can be laidon their sides on top of each other,using wedges as necessary.Otherwise they should be stacked incases, boxes, cartons or racksdesigned to hold them.

If pallets are used, spacers orsome form of horizontal bondingshould be incorporated. The overallweight of stacks should not be borneby the glass itself.

DRUMS, CASKS ANDCYLINDERS

Drums, casks and cylindersmay be stacked on their sides or endsunless specifically required to stand

upright on instructions from theirmanufacturer or supplier, e.g.acetylene cylinders. If stacked ontheir sides, wedges should be fixedat the ends of each row to preventmovement.

If gas cylinders are stored onend, restraining chains should befitted to prevent them toppling. Thevalves of gas cylinders underpressure must always be protected.

Power-operated clamps onforklift trucks enable cylindricalobjects such as cable drums or pipesto be stacked on end, allowinggreater economy of space andgreater stability.

SHEET MATERIALS

Sheet materials, includingglass, may be stacked flat or on edge.Sharp edges should be protected toprevent injury to workers andpassers-by. The supports used inedge-on stacking must be ofadequate strength to bear the sidethrust of the vertical sheets.

Extra care should be takenwhen stacking and handling glass.Owing to the weight of metal andglass sheet in bulk, care should betaken not to overload racks and thefloor.

Drum rack

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STEEL TUBES BARS ANDJOIST SECTIONS

Suitable racks should beprovided for steel tubes, bars, joistsections and similar materials.Large-diameter tubes or pipes can bestacked on their sides, as for drums.

Wedges, chocks, stakes orother means should be used torestrain the bottom tier of roundobjects which are stacked or tieredand which could cause the stack tocollapse by rolling or moving.

Where successive tiers are notnested but rest on battens, planks orother flat surfaces, they should berestrained from moving by wedgessecured to the battens or planks.

Where the collapse of a stackor tiers of round objects could causedamage or injury, material to beremoved should always be takenfrom the top of the stack or from thetop tier first.

Destacking is largely the reverseprocess of stacking. Most

accidents involving the collapse ofstacked materials occur duringdestacking. The prime cause of thisis haphazard removal.

Basic rules for breaking downstacks are:— One person only should be re-

sponsible for the manner in

Rules for Destackingwhich the stack is reduced. Thisis particularly important wheregangs are employed.

— If the person in charge ofdestacking had no part in erect-ing the stack, he or she shouldascertain its construction beforework begins.

Pipe storage

Steel storage

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— The stack should be taken downtier by tier, so that no part is indanger, as would happen if thestack were bitten into locally.

— When a large stack has beengiven a natural fence by build-ing the periphery higher than thecentre, this fence should bemaintained during destacking.The work should be done out-ward from the centre, reducingthe periphery last so that thereis a barricade to prevent peoplefalling off.

– If tubular or other fencing hasbeen built in or around the stack,

it should be dismantled and ad-justed as the height is de-creased.

— As there is a high tripping haz-ard in the working area of astack, tidiness and systematicwork methods are essential.

Care should be taken to ensurethat people working on stacks areat all times clear of overheadtravelling cranes. Proper signallingarrangements should be made anda lookout should be posted.

All stacking and destackingshould be carried out undercompetent supervision.

Segregation of Stock

F lammable liquids, gas cylinders,aerosols, materials liable to

spontaneous combustion andhazardous chemicals should not be

stored in the same area as othergoods.

Chemicals liable to react witheach other or other materials should

Flammable liquid storage

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not be stored together unlessadequately protected fromcontacting each other, either directlyor by spillage. (The chart inAppendix 1 gives a guide tochemicals which should notnormally be stored together.)

Acids should not be stored inplastic containers for long periods orin direct sunlight.

Flammable liquids in drums,cans or similar containers should bestored separately in a separate areaor building constructed for thepurpose. Similar provision isrecommended when storing toxic orpoisonous chemicals or substances.

The storage area or buildingshould be signposted to indicate thatit contains flammable or hazardouschemical materials and that smokingand naked flames are prohibited.

Electrical equipment used in or

around the storage area orbuilding should be suitablyexplosion-protected, and protectiveequipment should be providednearby for use in emergencies.

Workers handling corrosive orhazardous chemicals should beprovided with suitable protectiveclothing, or other necessarysafeguards.

Liquefied and compressed gascylinders should be stored in wellventilated areas, out of directsunlight and well away frompossible sources of ignition,especially electrical fittings or fuseboxes.

All containers, drums and cansshould be clearly labelled with theircontents.

Earthing or bonding should beused to eliminate the possiblebuild-up of static electricity.

Earthed containers for storing flammable solvents

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Fire Safetyof such goods, inwards or outwards,should be notified to the local firebrigade immediately.

Bulk storage of combustiblesshould be sited so as to, minimisethe risk of fire occurring within thestack or spreading from adjacentareas. In general, stacks should beat least 2 m clear of perimeterboundaries and be divided by cleared

F ire instruction notices should beprominently displayed in all

storage areas. Workers should bethoroughly trained in the operationof the fire alarms to prevent delaysin evacuating the premises andcalling the fire brigade in the eventof a fire. They should also be trainedto operate firefighting equipment todeal with small fires.

A ‘No Smoking’ rule should bestrictly enforced in all storage areas.

If a shrink-wrapping operationis used, it is important to trainoperators to ensure that the plasticshroud is cut large enough tocompletely cover the goods duringthe shrinkage process. If the plasticshroud shrinks and exposes thebottom part of the goods, the sewnedges of the sacks or bags maybecome scorched. Fires haveoccurred when the sacks are placedin the store while smouldering.

There should be no plant orproduction processes, such as cartonassembly, in storage rooms unlessthe area is designed for the purposeand any necessary precautions taken.Vehicles should not be garaged orrefuelled close to stored material.

An inventory of all goods heldin store should be kept andmaintained daily, especially forhazardous chemicals and substancesand flammable goods. The local firebrigade should be advised of thegoods and quantities stored at leaston a weekly basis. Large movements

Fire-fighting equipment and emergency route sign

gangways of at least 1 m.These clearances may need to beextended for stacks of readilycombustible materials.

Smoking should not beallowed within 6 m of stacks.Incinerators should be sited wellclear of the storage area andcombustible materials.

Undergrowth around outdoorstacks should be kept down,although never by burning or byusing weed killers which aidcombustion (e.g. sodium chlorate).

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A ll materials held in storageshould be inspected to

determine whether they aresusceptible to damage, heating,deterioration, swelling, shrinking,corrosion or attack by insects orrodents. The frequency of inspectionwill depend on the type and methodof storage. Where these conditionsare evident and could cause loss ofstability, collapse, fire or any otherharmful effect, action should betaken to eliminate the hazard.

Incoming goods should becarefully inspected for damage ofany kind before being placed instore.

Racks, shelving, fixtures andother equipment used for storing,loading and unloading materialsshould be regularly inspected fordamage and other defects whichmight cause loss of strength or resultin damage or injury.

Any damaged or defective

Storage Inspectionsequipment should be taken out ofservice until repaired. Fencing off orisolation of such equipment may benecessary to prevent its use.Electrical equipment and fittingsshould also be inspected and testedregularly.

All fire protection equipment,including fire doors and partitions,should be inspected, tested regularlyand be maintained in good workingorder. Fire doors should be keptclosed at all times unless required tobe opened for the movement ofgoods.

Any repair, maintenance oralteration work carried out in storageareas should be closely supervisedto ensure the safety of workers andother people on the premises.

Use of equipment likely to giverise to a fire hazard should be closelymonitored, and the use of a hot workpermit system is recommended.

Outdoor storage area showing minimum distances for storing items vulnerable to fire

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Equipment such as trolleys, handtrucks, pallet trucks,

chainblocks and slings used formoving and handling materialsshould be kept in a safe andserviceable condition. It should befree of cracks or other defects whichcould cause failure of the equipmentor injury to employees using it. Suchequipment should be used only forthe purpose for which it wasdesigned.

Mechanical equipment such ascranes, hoists, scoops, stackers,forklift trucks and ladders used instacking, moving or loadingmaterials should be kept in a safe andserviceable condition, and should beregularly inspected and maintained.

Materials handling equipmentshould be used only for the purposesfor which it was designed and shouldnot be operated on steep or roughsurfaces which could result in anaccident.

No worker should ride onequipment used for the moving,handling or storage of materialunless it has been designed for thepurpose.

All equipment should beoperated in a safe and efficientmanner and should not be loadedbeyond the capacity for which it wasdesigned.

Materials handling equipmentis susceptible to fire from frictionheat generated by accumulations ofgrease and dirt. Fires involvingforklift trucks can be caused byequipment failure due to lack ofmaintenance.

Materials Handling Equipment

Block and tackle

Dolly

Platform truck

Drum-handling truck

Bag truck

Hoist

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All such equipment should beinspected regularly and maintainedin good working order. A system ofregularly scheduled maintenancebased on engine-hour or motor-houruse is recommended.

G oods must be stacked toprevent movement during

transportation and be secured so thatthey will not fall off when cornersor inclines are being negotiated.

Precautions must be taken toprotect workers in the storage areafrom moving vehicles. If necessary,a responsible employee should bedesignated to direct traffic in thestorage yard or area.

Good lighting is essential, andthe wearing of reflective clothingwill increase safety.

Forklift trucks should be fittedwith horns and lights and theseshould be used, especially whenreversing.

Special care must be taken inhandling and transportingflammable liquids. These should notbe stored at an unsafe height.

Safe Stock Movement

Forklift truck:

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Where automated, computer orremote controls are used for

racking, selection of materials orother stores functions, care shouldbe taken that workers or other peoplein the area are not exposed to risk ofinjury through the operation ofequipment.

Automated storage equipmentis designed for machine access,which can create hazardous areasbetween moving equipment andfixed installations. Non-essentialpeople should therefore be keptaway from operating areas.

Automated equipment shouldbe isolated, or manual controlapplied, before attempting to rectifyfaults, particularly if parts of theequipment are extended.

A means of access or egressfrom extended equipment must beprovided to eliminate the need toescape through any racking systeminstalled.

Controls should be such that,when switched from thedisconnected “off” mode back toautomatic, the previous cycle isunable to continue until a resetcontrol has been operated.

Access to racks from other thanthe operating side should beprevented unless complete safety isassured.

Conveyors and elevatorsshould be properly guarded and becapable of being isolated fromautomatic control.

Automated Storage

Waste should not be allowed toaccumulate. A regular and

frequent waste removal and cleaningprocedure should be adopted.

HousekeepingStorage areas should be kept

clean and free from all refuse andincorrectly stored materials.

Fire exits must never beblocked

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Sufficient and suitable lighting,whether natural or artificial, must

be provided in every part of anundertaking where workers areemployed or pass. This includesoutside yards and storage areas.Lighting in these areas should be suchthat dark shadows or glare is avoided

Lightngon the working area of stacks andstorage fixtures. Lighting can besupplemented by paintingappropriate surfaces white oroff-white.

Appropriate lighting standardscan be found in NZS 6703:1984Interior Lighting design.

Employers are required to take allpracticable steps to protect

workers from harmful noise, eitherby controlling the noise at source orby isolating or insulating the noisyactivity or process. Where suchcontrols are impossible or

Noiseimpracticable, or in the interimperiod while controls are beingdeveloped, the employer mustprovide, for each worker exposed,individual hearing protection of atype approved by OSH.

P rotective clothing andequipment such as overalls,

aprons, gloves, gauntlets, leggings,safety helmets, ear protection, eyeprotection (face shields and safetyglasses), safety footwear, facemasks, respirators, safety harnesses,belts or other equipment must beprovided by the employer as and

Protective Clothing and Equipmentwhen necessary.

Employees must wear theprotective clothing and equipment asand when necessary.

If hazardous chemicals orsubstances are stored, e.g. corrosiveacids, an emergency shower and eyewash should be installed in eachstorage area.

E mployees involved in thestorage, stacking, loading and

unloading of materials must betrained to carry out their tasks safelyand efficiently. They should be madeaware of the nature of the goodsstored, the hazards involved and theprecautions to be taken, protectiveclothing and equipment to be worn,and action to be taken inemergencies. Employees operating

mechanical equipment need specialtraining for the particular types ofequipment used.

The correct method of dealingwith breakages or spillages andneutralising hazardous chemicalsand substances should also beexplained.

Fire safety, including the useof fire-fighting equipment, should bepart of all training.

Training of Employees

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Tolu

ene,

xyl

ene

Styr

ene

Othe

r hyd

roca

rbon

sol

vent

sTr

ichl

oroe

thyl

ene

Met

hyle

ne c

hlor

ide

Form

alde

hyde

Phen

olHy

drog

en p

erox

ide

Orga

nic

pero

xide

sNi

trate

sCh

rom

ates

, dic

hrom

ates

Chlo

rate

s, p

erch

lora

tes

Pota

ssiu

m p

erm

anga

nate

Hypo

chlo

rites

Saw

dust

Hydrochloric acid

Sulphuric acid

Phosphoric acid

Nitric acid

Perchloric acid

Acetic acid

Caustic soda

Sodium carbonate

Ammonia solution

Cvanides

Aluminium

Magnesium

Other metals

Acetone

Methyl ethyl ketone

Alcohols

Kerosine, white spirit

Toluene, xylene

Styrene

Other hydrocarbon solvents

Trichloroethylene

Methylene chloride

Formaldehyde

Phenol

Hydrogen peroxide

Organic peroxides

Nitrates

Chromates, dichromates

Chlorates, perchlorates

Potassium permanganate

Hypochlorites

Sawdust

This

cha

rt is

a g

uide

onl

y to

che

mic

als

whi

ch s

houl

d no

t nor

mal

ly b

e st

ored

toge

ther

.It

is n

ot a

n al

l-inc

lusi

ve li

st a

nd c

erta

in fa

ctor

s su

ch a

s st

reng

hth

of a

cidi

c so

lutio

ns m

ay a

lter t

he s

tora

ge re

quire

men

ts.

Saw

dust

is in

clud

ed p

urel

y to

indi

cate

that

it s

houl

d no

t be

used

to n

eutra

lise

any

spill

age

of th

e ch

emic

als

indi

cate

d or

to p

ack

them

.

Appendix: Incompatible Chemicals